Methods of making an improved photoreceptor outer layer
First Claim
Patent Images
1. A method for forming an imaging member having a patterned surface in the outer layer, comprising:
- providing a mold for imprinting, wherein the mold comprises a pattern on one face of the mold, the pattern comprising an array of periodically ordered protrusions or indentations and wherein the step of providing the mold for imprinting further comprisesink-jet printing a nano- or micron-scale pattern onto a substrate to create a master pattern,applying a flexible material onto the master mold,curing the flexible material onto the master pattern to form the mold,removing the master pattern to produce a flexible mold;
providing an imaging member comprising a substrate and disposed thereover the substrate a soft outer layer coating for being imprinted;
applying one or more release agents onto the mold prior to imprinting the outer layer coating;
pressing the patterned face of the mold and the outer layer coating of the imaging member together in a manner such that the pattern structure of the mold is replicated onto the outer layer coating; and
hardening the outer layer coating to form a patterned structure on an outer surface of the imaging member.
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Abstract
The presently disclosed embodiments relate generally to layers that are useful in imaging apparatus members and components, for use in electrophotographic, including digital, apparatuses. Embodiments pertain to an improved electrophotographic imaging member incorporating an outer layer having a nano- to micron-scale pattern imprinted into its surface to lower friction with the cleaning blade and improve print quality and performance. Embodiments also pertain to methods for making the improved imaging member.
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Citations
21 Claims
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1. A method for forming an imaging member having a patterned surface in the outer layer, comprising:
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providing a mold for imprinting, wherein the mold comprises a pattern on one face of the mold, the pattern comprising an array of periodically ordered protrusions or indentations and wherein the step of providing the mold for imprinting further comprises ink-jet printing a nano- or micron-scale pattern onto a substrate to create a master pattern, applying a flexible material onto the master mold, curing the flexible material onto the master pattern to form the mold, removing the master pattern to produce a flexible mold; providing an imaging member comprising a substrate and disposed thereover the substrate a soft outer layer coating for being imprinted; applying one or more release agents onto the mold prior to imprinting the outer layer coating; pressing the patterned face of the mold and the outer layer coating of the imaging member together in a manner such that the pattern structure of the mold is replicated onto the outer layer coating; and hardening the outer layer coating to form a patterned structure on an outer surface of the imaging member. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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20. A method for forming an imaging member having a patterned surface in the outer layer, comprising:
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providing a mold for imprinting, wherein the mold comprises a pattern on one face of the mold, the pattern comprising an array of periodically ordered protrusions or indentations and wherein the step of providing the mold for imprinting further comprises ink-jet printing a nano- or micron-scale pattern onto a substrate to create a master pattern, applying a flexible material onto the master mold, curing the flexible material onto the master pattern to form the mold, removing the master pattern to produce a flexible mold; providing an imaging member comprising a substrate and disposed thereover the substrate a soft outer layer coating for being imprinted; applying one or more release agents onto the mold prior to imprinting the outer layer coating; pressing the patterned face of the mold and the outer layer coating of the imaging member together in a manner that the pattern structure of the mold is replicated onto the outer layer coating; and hardening the outer layer coating to form a patterned structure on an outer surface of the imaging member, wherein the periodically ordered protrusions have a height of from about 100 nanometers to about 2 microns and the indentations have a depth of from about 100 nanometers to about 2 microns.
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21. A method for forming an imaging member having a patterned surface in the outer layer, comprising:
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providing a mold for imprinting, wherein the mold comprises a pattern on one face of the mold, the pattern comprising an array of periodically ordered protrusions or indentations and wherein the step of providing the mold for imprinting further comprises ink-jet printing a nano- or micron-scale pattern onto a substrate to create a master pattern, applying a flexible material onto the master mold, curing the flexible material onto the master pattern to form the mold, removing the master pattern to produce a flexible mold; providing an imaging member comprising a substrate and disposed thereover the substrate a soft outer layer coating for being imprinted; applying one or more release agents onto the mold prior to imprinting the outer layer coating; pressing the patterned face of the mold and the outer layer coating of the imaging member together in a manner that the pattern structure of the mold is replicated onto the outer layer coating; and hardening the outer layer coating to form a patterned structure on an outer surface of the imaging member, wherein the array of periodically ordered protrusions or indentations are regularly positioned over a surface of the outer layer and further wherein each of the indentations and protrusions has a perimeter of from about 5 nanometers to about 200 microns.
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Specification